INDEX for FORMS
Under the Indian Boiler Regulations, 1950
___________________________________________________________________________
Form No.
Description
Page
___________________________________________________________________________
Form I
Memorandum of Inspection or Registration Book
3 - 11
Form II(1)
Certificate of Inspection for Shop Assembled Boilers
12
Form II(2)
Certificate of Inspection for Site Assembled Boilers
13
Form II-A
Inspecting Authority Certificate of Inspection during
Construction in respect of the boiler made to foreign code
14
Form II-B
Inspecting Authority Certificate of Inspection during the
Inspection of boilers for which variation from standard
Have been permitted
15
Form II-C
Inspecting Authority Certificate of Inspection during Erection
16
Form III
Constructor's Certificate of Manufacture and Test
17-21
Form III-A
Certificate of Manufacture and Test for Pipes
22-23
Form III-B
Certificate of Manufacture and Test for tubes
24-25
Form III-C
Certificate of Manufacture and Test of Boiler mounting
And Fittings.
26-27
Form III-D
Deleted
28
Form III-E
Deleted
28
Form III-F
Certificate of Manufacture and Test of castings
29
Form III-G
Certificate of Manufacture and Test of Forgings
30
Form III-H
Certificate of Manufacture and Test for Headers, Desuperheaters/
Attemperator, Blowdown Tank, Feed Water Tanks, Accumulator,
Deaerator
31-32
Form III-I
Certificate of Manufacture and Test for Dished Ends/End Covers
33
Form IV
Steel Marker's Certificate of Manufacture and results of Test
34
Form IV-A
Certificate of Manufacture and Results of Tests in lieu of original
Test Certificates
35
Form V
Provisional Order under section 9 of the Boilers Act, 1923
36
Form VI
Certificate for use of a Boiler
37-38
Form VII
Inspecting Authority's Certificate of Inspection under
Construction
39
Form VIII
Constructor's Certificate of Manufacture and Test
40
1
Form IX
Memorandum of Inspections of Registration Book(Economisers)
41-44
Form X
Provisional Order under the Boilers Act,1923
45
Form XI
Certificate for the use of an Economiser
46-47
Form XII
Record of Welder's Qualification/Requalification Tests
48-49
Form XIII
Qualified Boiler Welder's Certificate
50
Form XIV
Steam Pipes and Connecting Fittings
51-53
Form XV-A
Questionnaire Inspecting Authority
54-56
Form XV-B
Questionnaire Competent Authority
57-58
Form XV-C
Questionnaire Well Known Steel Maker
59-60
Form XV-D
Questionnaire Well Known Foundry/Forge
61-62
Form XV-E
Questionnaire Well Known Tube/Pipe Maker
63-64
Form XV-F
Questionnaire Well Known Material Testing Laboratory
65-66
Form XV-G
Questionnaire for Well-known Remnant Assessment Organisation
67-68
Form XVI-A
Certificate of Approval for Inspection Authority
69
Form XVI-B
Certificate of Approval for Competent Authority
70
Form XVI-C
Certificate of Approval for Well Known Steel Maker
71
Form XVI-D
Certificate of Approval for Well Known Foundry
72
Form XVI-E
Certificate of Approval for Well Known Forge
73
Form XVI-F
Certificate of Approval for a Well Known Tube Maker
74
Form XVI-G
Certificate of Approval for Well Known Pipe Maker
75
Form XVI-H
Certificate of Approval as Well Known Material Testing
Laboratory
76
Form XVI-I
Certificate of approval as Well known Remnant Life
Assessment Organisation
77
Form XVII
Certificate of Manufacture and Test for Small Industrial
Boilers including Small Industrial Solar Boilers
78-79
Form XVIII
Questionnaire form for repairer of boilers/ economizer/ steam line/
feed water lines
80-81
Form XIX
Details to be furnished alongwith application for inspection of
Boiler after twelve/ Twenty four months of certification under
Regulation 390 as per Appendix “JA’ and Appendix ‘JB’
82-84
2
“FORM I
(See regulation 386)
MEMORANDUM OF INSPECTION BOOK
OR
REGISTRATION BOOK
BOILER INSPECTION DEPARTMENT
BOILER REGISTRY NUMBER
3
GENERAL
District…………………………………………
Owner…………………………………………
Address of Factory…………………………..
Nearest Railway Station…………………….
Factory is……………………………………..
KMs ………………………………… from station
Work or Factory…………………………..…..
Working Season …………………………….
Boiler registered at……………………………
on………………………………………………………
Register Book No. ……………………………
Page…………………………………………………..
Registry Number………………………………
verified on…………………………………………….
Approved Working Pressure
Boiler Rating……………………………………
Registration Book Filed at…………………….
Inspection Fee………………………………………..
on………………………………………………. …….
Remarks on transfers, etc.
PROVISIONAL ORDER AND CERTIFICATE RECORD
Fee
Rs
Date of
Payment
Date of
Inspection
Certificate
No. and Date
Period of
certificate
Working
Pressure
Kg/cm2
Boiler
Rating
PARTICULARS AND DIMENSIONS
Type of Boiler:
Leading Dimensions:
Maker:
Intended Working Pressure :
Place and Year of make :
Maker’s Number :
Description of Boiler:
Details of Maker’s stamp
4
Evaporation
T/hr or Kg/hr
Initials of
Inspector/
Competent
Person
Position of Stamp ……………………
MAKER’S CERTIFICATE
Boiler
Name………………………
Maker
Manufacture, hydraulic test to
received……………
…………… Kgs/Cm². Drawing No.……
Inspecting Name………………………
Authority Tests of material, construction,
received…………..
supervision, hydraulic test………………
DETAILS OF PRESSURE PARTS
S NO
NAME OF THE PRESSURE PART
SIZE
MATERIAL SPECIFICATION
CYLINDRICAL SHELL
(a)
Shell or Mud Drum
Name of parts
Number
Length between end plates
Length between end plates seam
Diameter inside largest belt
Thickness of Plates
Number of belts of plating
Longitudinal seams
Position (o’clock)
5
(b)
Steam Drum
Circumferential seams
No. of seams (end and inner)
STAYS
PLATES
SHELL END PLATES AND STAYS
Flat, dished, hemispherical (in………………………………………. pieces,) not stayed, not flanged
Diameter (outside), front………… back,………...
crown…………………
Largest circle …………..
Radius of curvature front………………………….
back, …………………
crown …………………...
Radius of curvature, corner of flange,…………...
shell, …………………
furnace, …… uptake, …
Plate, thickness, front …………… back, ……….
crown…………………
tubeplate F,…….. B, ….
Attach. to shell, crown or front, ………………….
Attach. to shell, back end, ………………………..
Attach. to uptake or furnace crown or front,…….
Attach. to furnace flue, back end………………...
Gusset Stay, No. F.E., top, …………
Bottom, …………..
B.E., top, ………...
bottom, …………..
Longtl. Stays No. …………………….
dia., ……………....
………….
, …………...
Longtl. Stays pitch, Vertical ……..
Horizontal…………
…....
Circumferential
………...
Diagl. Do, …………………………………………………………………………………………………….
MANHOLES, HAND AND SIGHT HOLES, DOORS AND STAND BLOCKS
Parts and materials
hereunder......................................................................……………………..
No. and position
MANHOLES
Framed or plate flanged
Boiler opening, length × width
Frame opening, length × width
Frame inside, outside, raised, pressed
Frame solid, welded, cast
Frame section on longtl. axis
6
Door, type and thickness
Door, if inside, spigot clearance
Bolts, No. dia., threads Nut
Bolts, pitch circle
BLOCK
ETC.
SIGHT
HOLES
Compensation ring, width x thickness
No. …………………………………...
dimensions …………………….
positions ………………..
Compensation rings fitted …………
section …………………………
Doors, type ………………………….
bolts dia.,…….. threads………
spigot clearance………..
Cleaning plugs, No …………………
dia. ……………………………..
position …………………
Height ………………………………..
dia. (outside), top,… bottom….
thickness ………..……...
Standpipe below stop valve, ………
height,…… dia. (outside) ……
thickness ………..……...
Flanges ……………………………...
FIREBOX DETAILS
II &III PASS TUBES
I &II PASS TUBES
DETAILS OF FLUE TUBES
No. plain, ………………...
Stay
overall
Plain, dia. (out) ……….....
thickness, …
Front End.,welded, expd., beaded, feruled. Smoke End.,welded
Expd., beaded, or …..
Stay, dia. (out) ………......
thickness, ………….
F.E.,welded, expd., beaded, , S.E,welded, Expd., ..
Pitch of plain tubes, V ….
H …………………....
D …………. C.Z. ………….
Pitch of stay tubes, V …..
H…………………….
D ………….. C, Z ………….
overall
length …… specification ………..
No. plain, ………………...
Stay
Plain, dia. (out) ……….....
thickness, …
Front End.,welded, expd., beaded, feruled. Smoke End.,welded
Expd., beaded, or …..
Stay, dia. (out) ………......
thickness, ………….
F.E.,welded, expd., beaded, , S.E,welded, Expd., ..
Pitch of plain tubes, V ….
H …………………....D ……….
Pitch of stay tubes, V …..
H…………………….
7
length …… specification ………..
D ………..
C.Z. ………….
C, Z ………….
HORIZONTAL AND VERTICAL
FURNACES
FURNACE, CROWN AND UPTAKE
No., ………………………………
No. of stiffener rings in each Furnace………………………
Type …………………………………
Longtl. seams position
Length between
Centre
Inside diameter
Plate thickness
Positions of cross
tubes or stiffener
MOUNTINGS AND FITTINGS
MISCELLANEOUS FITTINGS
Valves etc.
Number
Diameter
Type
Material
Bolted OR welded
to
Safety
Safety
Main. Stop
Aux. Stop
Feed
Blow Down
Injector
Water gauges, No. ………………………… type ………………… Test cocks No. …………………
Water gauges, top of lower nut is ………… ……………………… mm above …………………..
Pressure gauge, Type …………………….. dia.in mm
… range ………
Kg/cm²
Pressure gauge, Maker …………………… No. …………. red line at …………… Kg/ cm²
Fusible plug, type …………………………. ………………………. position ………………………….
Blow down pipe connected to ……………………
Feed apparatus ……………………………………………………………………………………………
Additional fittings ………………………………………………………………………………………….
8
SAFETY VALVES
(A)
(B)
(C)
No. of valves each chest ……….
Type ………………………………
Diameter of valve seat(mm)..
Diameter of Neck(mm)………..
Diameter of outlet(mm)……….
……………………………………..
REQUISITE AREA OF SAFETY VALVES
For Saturated steam
A
For Superheated steam
E
C.P.
As
E=
;C=
;P=
;A=
As =
;T=
;A=
;
A
HEATING SURFACE
Total Heating Surface ………………………………………………Sq. m.
Boiler Rating ……………………………………………………………………………………..……
9
1
1.5T
1000
HYDRAULIC TEST (REGISTRATION)
Inspector ……………………… Date of test ……………………… Test pressure .……………… Kgs/ cm²
Duration of test …………… mins. Boiler pressure, gauge No. …..…………… use at test ………………..
Boiler pressure gauge compared with ……………... on …………………… found ………………………….
Position of Boiler at test ……………………………………………………………………………………………
Brick work ……………………………………… Lagging ………………..………………………………………
Condition of boiler under test ……………………………………………………………………………………..
Condition of boiler mountings under test ……………………………………………………...…………………
M I book prepared by …………………… on ……………………… submitted on ……………………….
M I Book Checked by ………………….. on ………………………………………………………………..
Least pressure, that for………………………………………………………………………………Kg/ cm²
Approved working pressure………………………………………………………………………… Kg/ cm²
Chief Inspector/Director of Boiler’s remarks and signature ………………………………………………
STEAM TEST (REGISTRATION)
Approved working pressure ………. .Kg/ cm²
Date of Test ………………………………………. …
Test pressure ……….. Kg/ cm²
Boiler connections ………………………………………
Condition of fire …………………………………...
Fuel used ………………………………………………..
Draught …………………………………………….
Safety Valve lifted at (A) ……
(B) ……
Inspector …………………………………………………
kg/ cm²..
Beginning
5 mins.
kg/ cm². (C) ……
10 mins.
kg/ cm²..
15 mins.
Difference
Timing of test…………………………….
Height of water in glass…………………
Pressure by Boiler gauge……………….
Accumulation of pressure, in (% )………………………………………………………………………..
Do safety valves efficiently relieve boiler? …………………………………………………………………….
Condition of boiler under steam …………………………………………………………………………………
Condition of mountings under steam …………………………………………………………………………..
Thickness of washers or ferrules ……………………………………………………………………………….
Feed pump or injector worked …………………………………………………………………………………..
Water gauge tested ………………………………………………………………………………………………
Boiler Attendant (or) Boiler Operation Engineer ……………………………………………………………..
Limit of load on safety valves to be entered in Certificate ……………………………………………………
10
NOTES ON WORKING OF BOILER
Boiler is used for ……………………………………………………………………………………………..
Constant, intermittent or seasonal work ……………………………………………………………………
Is boiler relieved by spare boiler ? ………………………………………………………………………..
Nature of feed water ……………………………………………………………………………………………….
Fuel used …………………………… Are printed instructions kept near boiler ? ………………………
Period between cleanings recommended by Inspector ……………………………………………..
____________________________________________________________________________________
STEAM-PIPES
PLAN OF MAIN STEAM-PIPES
Registry Nos. of connected boilers ……………………………
Provisions for disconnection from other boiler ………….
RECORDS OF INSPECTIONS AND TESTS
First inspection by …………………… on ……………………
First hydraulic test to
Kgs/ cm² … by ……………………… on ………………………
INSPECTION NOTES
PARTICULARS OF BOILER ATTENDANTS &BOILER OPERATION ENGINEER
Date of visit
Name
Grade
”.
11
Certificate No.
Date of Issue”.
“FORM II (1)
[See regulation 4(c)(i) ]
CERTIFICATE OF INSPECTION FOR SHOP ASSEMBLED BOILERS
INSPECTING AUTHORITY:____________________________________ Certificate No._____________
We hereby certify that the ________Boiler, built by M/s________________________
_______________________________________________________________________
under Maker’s number ____________ was constructed under our supervision and
inspected at various stages of construction by the
Competent Person and that the
construction and workmanship were satisfactory and in accordance with the standard
conditions for the design and construction of boilers as per regulations framed under the
Boilers Act, 1923.
The boiler is stamped on the ________________ Shell Plate with stamp as shown
hereunder:MAKER’S NAME
: _____________________________________
MAKER’S NO.
: __________
TESTED TO
: _______ Kg./cm² (g)
W.P.
: _______ Kg./cm² (g)
YEAR OF MAKE : _________
ON : _______________
COMPETENT PERSON’S OR INSPECTING AUTHORITY’S OFFICIAL STAMP
The boiler on completion was
subjected to a Hydrostatic test pressure of _____
kg/cm² (g) in the presence of the Competent Person on _____ day of ______________
and satisfactorily withstood the test.
All welded seams were subjected to destructive and Non-Destructive examination wherever
applicable and found satisfactory.
We have satisfied ourselves that the construction and dimensions of the boiler are as shown
in the Maker’s Drawing Number _____________________________________ signed by
us and that the particulars entered in Maker’s certificate of manufacture in Form III
countersigned by us are correct to the best of our knowledge and belief.
Signature of Competent Person
Signature of Inspecting Authority
Date and Seal
12
FORM II (2)
[See regulation 4(c)(i) ]
CERTIFICATE OF INSPECTION FOR SITE ASSEMBLED BOILERS
INSPECTING AUTHORITY :____________________ Certificate No. ____________
We hereby certify that the__________ boiler; built by M/s___________________
_________________________________________________________________________
under Maker’s Number _______________ was constructed under our supervision and
inspected at various stages of construction by the Competent Person and that the construction
and workmanship were satisfactory and in accordance with the Standard Conditions for the
design and construction of boilers as per regulations framed under the Boilers Act,1923.
The Boiler components are stamped as per details below, wherever applicable.
Component Name
Drawing No.
Stamping Details
Maker’s Name :_____________________
Maker’s Number :____________________ Year of make :________
Tested to
:_______________ Kg/cm²(g) on ___________
W.P.
: _______________ Kg/ cm² (g)
Competent Person’s or Inspecting Authority’s Official Stamp
Samples of materials used in the constructions of the boiler were tested in the presence of the
Competent person and found to comply with the regulations.
All welded seams were subjected to destructive and Non-Destructive examination wherever
applicable and found satisfactory.
We have satisfied ourselves that the construction and dimensions of the boiler are as shown in
the Maker’s Drawing Number___________________ signed by us, and that the particulars
entered in the Maker’s certificate of manufacture in Form III countersigned by us are correct
to the best of our knowledge and belief.
Signature of Competent Person
Signature of Inspecting Authority
Date and Seal ”.
13
FORM II-A
INSPECTING AUTHORITIES CERTIFICATE OF INSPECTION DURING
CONSTRUCTION IN RESPECT OF A BOILER MADE TO FOREIGN CODE FOR EXPORT
[Regulation 3A]
Designation of Inspecting Authority
We hereby certify that the ……………… type boilers; length ……………… diameter ………………
working pressure ……………… built by Messrs ……………… under Shop No. ……………… was
constructed under our supervision and inspected at various stages at construction by the Competent Person and
that the design, construction and workmanship were satisfactory and in every respect in accordance with
……………… Code Specification. The boiler is stamped as under :
The boiler on completion was tested to ……………… in the presence of the Competent Person on
……………… and it satisfactorily withstood the test. Details of tests and inspections are furnished with this
certificate.
We have satisfied ourselves that the design, construction and dimensions of the boiler are as shown in
the Maker’s Drawing No. ………………… approved and signed by us, and that the particulars entered in the
Maker’s Certificate of manufacture are correct to the best of our knowledge and belief.
Maker’s certificate, signed by them and countersigned by us, as required by the ……………………
Code/Specification, is enclosed.
Signature of Inspecting Authority
14
FORM II-B
INSPECTING AUTHORITY CERTIFICATE OF INSPECTION DURING CONSTRUCTION
OF BOILERS FOR WHICH VARIATIONS FROM STANDARD CONDITIONS HAVE BEEN
PERMITTED
[Regulation 4(c)(1) Note]
Designation of Inspecting Authority
We hereby certify that the ……………… type boilers; length ……………… diameter ………………
working pressure ……………… built by Messrs ……………… at ……………… under Shop Number
……………… was constructed under our supervision and inspected at various stages of construction by the
Competent Person, and that the design, construction and workmanship were satisfactory and in accordance with
the variations from the standard conditions laid down in the Indian Boiler Regulations, 1950, for material design
and construction features have been permitted by the Board of Inspecting Authority under the Indian Boilers
Act, 1923.
The Boiler is stamped on the front end plate with our stamp as shown hereunder :—
Maker’s Name …………… Year of Make …………… Works Number …………… Tested to …………… on
……………… W.P. Competent Person’s or Inspecting Authority’s official stamp.
The boiler on completion was
subjected to a water pressure test of…………… in the presence of
The drum and header were
Competent Person on ……………… 20 ……………… and satisfactorily withstood the test.
*Samples of materials used in the construction of the boiler were tested in the presence of the
Competent Person and found to comply with the requirements. All welded seams were subjected to physical
tests and radiographic examination wherever applicable and found satisfactory.
Note: Strike off this paragraph where no such test have been carried out and the certificate in Form IV by a Well-Known
Maker is intended to be furnished.
* Strike out which is not applicable.
We have satisfied ourselves that the constructions and dimensions of the boiler are as shown in the
Maker’s Drawing No. ……………… signed by us and that the particulars entered in the Maker’s certificate of
manufacture in Form III countersigned by us, are correct to the best of our knowledge and belief. Particulars of
variations from the standard conditions laid down in the said regulations as permitted by the Board or Inspecting
Authority are enclosed.
Signature of Inspecting Authority
Dated at ………… this ………… day of ………… 20………
15
“FORM IIC
INSPECTING AUTHORITIES CERTIFICATE OF INSPECTION
DURING ERECTION
[Regulation 4 (c) (1)]
Designation of Inspecting authority
We hereby certify that the...............type boilers working
pressure.............................kg/square cm built by Messrs.................................
at........................... under makers number .............................. was erected under
our supervision and inspected at various stages of erection by the Competent
Person and that the erection and workmanship were satisfactory and in
accordance with the Standard Conditions for construction of land boilers under
the Indian Boilers Act, 1923.
All welded seams were subjected to post weld Heat treatment and Nondestructive examination wherever applicable and found satisfactory.
The boiler on completion of erection was subjected to a water pressure
tests of ...........................Kg per Square cm in the presence of the Competent
Person on............................and satisfactorily withstood the test.
We have satisfied ourselves that the erection of the boiler are as shown in the
Maker’s Drawing No...............................are correct to the best of our knowledge
and belief.
Signature of Competent Person
Signature of Inspecting authority
Dated at ............this............. Day of ..............20........ .”.
16
“FORM III
[See regulation 4(c)(ii) ]
Constructor’s Certificate of Manufacturer and Test
1. Description
Constructor’s Name and address…………………………………………………
Manufactured for/Stock purposes ………………………………………………..
Contract No. ………………………………………………………………………..
Type of Boiler …………………………………………………….. Length overall
Diameter inside Largest belt ………………………………………………………
Design pressure ……………………………………………………….. Kg/cm²
Reheater Pressure -------------------------------------- ------------------------Kg/ cm²
Maker Number of boiler ………………………………………………….
Year of Make ……………………………………………………………….
Total heating surface ……………………………………………………… Sq. m
Evaporation capacity ………………………………………………………………
(for calculation of relieving capacity of safety valves)
Final Temperature of steam (Design) Superheater Outlet…………ºC
Reheater Outlet ………… ºC
Brief description of boiler ………………………………………………………….
2. Parts manufactured at
the constructor’s works
Name of Components(s)……………………………………………….
Drawing No.…………………………………………….
Manufactured by ……………………………………………………………………
Identification marks ………………………………………………………………..
Part(s) manufactured, inspected at all stages of construction by ………………
(Inspecting Authority).
Part(s) hydraulically tested and inspected after test by …………….
3. Parts manufactured
outside the constructor’s
works
Name of Components(s) ……………………………………………………….
Drawing No.………………………….
Manufactured by ……………………………………………………………………
Identification marks ………………………………………………………………..
Part(s) manufactured, inspected at all stages of construction by ………………
(Inspecting Authority).
Part(s) hydraulically tested and inspected after test by …………….
Note: Similar information is to be furnished for each part manufactured outside the constructor’s Works.
17
4. Construction
(a) The construction is in accordance with Chapter III/ V / X / XII / XIV of the Indian Boiler
Regulations.
Number of longitudinal seams in shell/drum in each belt …………………………………..
Number of longitudinal seams in furnace in each ring ………………………………………
Number of circumferential seams in shell/drum ……………………………………………..
(including end seams) ………………………………………………………………………….
Number of circumferential seams in the furnace …………………………………………….
Details of repairs, if any, carried out in welded seams during construction ………………
Details of heat treatment ……………………………………………………………………….
All welded seams were subjected to Radiographic examination to the satisfaction of the
Inspecting Authority, where required.
Note : Strike out whichever is not applicable
1
2
3
4
5
6
7
*Indicate (1) Flat (2) Dished (3) Ellipsoidal (4) Hemispherical.
18
8
10
11
12
Hydrostatic test
lbs./sp.in
Type*
9
Radius of dish
in. mm
Head
Thickness in mm
Inside radius mm
Tube plate
Thickness in mm
Inside radius mm.
Thickness in mm.
Length
Nominal dia.
Nomenclature
No.
Shell plate
Manholes No. & Size
5. Details of Drums/Shells
13
6. Headers and Boxes
Description
Size and shape
Thickness in
mm
Head or end
Shape
Thickness in
mm
Hydrostatic test
Kg/ cm²
7. Mountings
No.
Nomenclature
1.
Main stop valve
2.
Auxiliary stop valves
3.
Safety valves
Material
(a)
(b)
(c)
4.
Blow down valves
5.
Feed Check valves
19
Type
No.
Size
8. Details of the safety valves and test results (Regulation 4 (c) (Vii)
Manufacturer ………………………………………………………………………………………………….
Identification marks of valves ……………………………………………………………………………….
Maker’s No. …………………………………………………………………………………………………..
Type ……………………………………………………………………………………………………………
Life (mm) ………………………… Drawings Nos. ………………………………………………………..
Valves details :
Material
…………………………………………………………………………………………………….
Valve Seat
………………………………………………………………………………………………….
Flat/Bevel
…………………………………………………………………………………………………..
Diameter of valve seating ………………………………………………………………………………..
Valve Body :
Material
…………………………………………………………………………………………………….
Opening at neck …………………………………………………………………………………………..
Opening at outlet ………………………………………………………………………………………….
Springs:
Material
……………………………………………………………………………………………………..
Process of manufacture …………………………………………………………………………………..
Chemical composition …………………………………………………………………………………….
Dimensions :
Outside diameter of coil …………………………………………………………………………………..
Section of wire …………………………………………………………………………………………….
Number of coils
…………………………………………………………………………………………….
Free length of coils ………………………………………………………………………………………..
Test results :
Place of test ………………… Date ………………………………………………………………………
Closing down pressure ……………………………………………………………………………………
Remarks :
Does the valve chatter? …………………………………………………………………………………..
Does the valve seat leak? ………………………………………………………………………………..
Blow off pressure ……………………………………………………………………………………….…
Type of valve and extract of test results ………………………………………………………………..
Type of valve
……………………………………………………………………………………………….
Place of test …………………………………………………………… date ……………………………
Constant ‘C’ by test results ……………………………………………………………………………….
Capacity of the valve for the intended blow off pressure ……………………………………………..
Signature of Maker’s representative
INSPECTING AUTHORITY witnessing tests
——————————————————————————————————————-20
9. Certified that the particulars entered herein in manuscript by us are correct and that
parts and fittings in sections 2 to 9, against the names of which entries are made have been
used in the construction and fittings of the boiler.
The particulars shown against the various parts used are in accordance with the enclosed
certificates from the respective Makers.
The design of the boiler is that as shown in Drawing Nos. ………
The boiler has been designed and constructed to comply with the regulations under the
Boilers Act, 1923, for a working pressure of ……………… Kg/ cm² at our Works abovenamed and satisfactorily withstood a water test of ……………… Kg/ cm² on the ……………
day of …………… 20 ……… in the presence of our responsible representative whose
signature is appended hereunder.
Least pressure is for (name of the component)____________ and is _____________
kg/cm²(g)
Maker’s Representative
Maker ___________________
(Name, signature and stamp)
(Name, signature and stamp)
Name, signature and stamp of
Competent Person
Name, signature and stamp of
Inspecting Authority
Dated …………… the day of …………… 20……”.
21
“ FORM III-A
[See regulation 4(e)]
Certificate of Manufacture and test for Pipes
Certificate No.--------------Date:------Name of part & Quantity…………………………………………………………………
Drawing No………………………………………………………………………….
Maker’s name and address…………………………………………………………..
Customer’s Name & Address……………………………………………………….
Design pressure………………Kg/cm²
Design temperature………….. ºC
RAW MATERIAL
Process of manufacture………………………………………………………………
Fully Killed/rimmed………………………………………………………………
Chemical composition…………………………………………….
Heat Number…………………………………………………………..
Size……………………………………………………………………………………
Test Certificate No. & Date………………………………………....
Name of the Steel Maker…………………………………………………………….
Name of Inspecting Authority……………………………………………………….
PIPES
Process of manufacture……………………………………………..
Main dimensions……………………………………………………………………..
Tolerances……………………………………………………………………………
Specification……………
Bend test on pipe or weld ……………………………………………………..
Flattening test………………………………………………………………………….
Other tests…………………………………………………………….
Tensile strength………………………………………………………………………..
Chemical Composition……………………………………………………………….
Heat treatment………………………………………………………..
Hydraulic test…… Kg/cm²
Identification mark of Inspecting Authority/Well known pipe maker …………………….
NOTE.- In addition, the following information in respect of the material shall be furnished in a tabular form in
conformity with the requirements of regulation 4(c)(vi) or the note thereto, as the case may be. The
information may be given from the established test data or if the material is of standard quality an
extract from the standard may be furnished instead.
Metal
temperature
250
275
300
325
350
375
400
C
Et
Sc
Sr
MAWP
Tensile strength at 20 C.
22
425
450
475
500
525
550
575
600
Where
Et = Yield point at temperature t (0.2% proof stress)
**Sc = Average stress to produce an elongation of 1% (creep) in 100,000 hours at various
working metal temperatures.
**Sr = Average and lowest stress to produce rupture in 100,000 hours at the various working
metal temperatures.
MAWP = Maximum Allowable Working Pressure in Kg./cm²
Temperature range in the table may extend upto the limit of applicability of the material.
**The value of Sc and Sr need be furnished only in respect of Pipes intended to be used for working
metal temperature above 454 C (850 F).
Certified that the particulars entered herein are correct. The particulars of fabricated component are
shown in drawing No. ..................
The pipe has been designed and constructed to comply with the Indian Boiler Regulations for a
maximum working pressure of _____________ Kg/cm² and maximum temperature of ____________ºC and
satisfactorily withstood a water test of ____ Kg/cm² on the ___________ day of ____________ 20___, in the
presence of our responsible representative whose signature is appended hereunder.
Maker’s Representative
(Name and signature)
Maker ___________________
(Name and Signature)
We have satisfied ourselves that the ________ have been constructed in accordance with Indian Boiler
Regulations 1950. The tests conducted on the samples taken from the finished pipes have been witnessed by us
and the particulars entered herein are correct.
Name and signature of
Competent Person
Name and signature of
Inspecting Authority/Well Known Pipe Maker
Place _______________
Date ________________
NOTE (1).- This form is intended for the use of both pipe manufacturers and pipe fabricators. Only
such of the columns or paragraphs that are applicable, or information that can be
obtained and furnished from other certificates, need be filled or entered in this form.
NOTE (2).- In the case of fabrications made from steel pipes obtained from elsewhere, particulars in
regard to the “material” and “pipes” shall be taken from similar forms of certificates
obtained in respect of pipes and noted in the appropriate columns or paragraphs.
NOTE-(3).- For Stock and sale purpose, one Form shall be issued for not more than five pipes.
In the case of pipes made from steel, made and tested by well known Steel Makers in India or
other countries, particulars regarding the ‘material’ as certified by them in Form IV shall be noted in
the appropriate columns or paragraphs of Raw material in this certificate.”.
23
“FORM III-B
[See regulation 4(f)]
Certificate of Manufacture and Test for Tubes
Certificate No.--------------Date:--------Name of part & Quantity…………………………………………………………………
Drawing No………………………………………………………………………….
Maker’s name and address…………………………………………………………..
Customer’s Name & Address……………………………………………………….
Design pressure……… Kg/cm²
Design temperature…….. ºC
RAW MATERIAL
Process of manufacture………………………………………………………………
Fully killed/rimmed……………………………………………
Chemical Composition……………………………….
Heat Number………………………………………..
Size…………………………………………………………………
Test Certificate No. & Date………………………………………....
Name of the Steel Maker…………………………………………………………….
Name of Inspecting Authority……………………………………………………….
TUBES
Process of manufacture………………………………………………………………
Main dimensions……………………………………………………………………..
Tolerances……………………………………………………………………………
Specification…………………………………………………………………..
Tensile strength………………………………………………………………………
Chemical Composition………………………………………………………………
Elongation percentage……………………………………………………………….
Bend test……………………………………………………………………………..
Flattening test………………………………………………………………………..
Crushing test…………………………………………………………………………
Flare test……………………………………………………………………………..
Flange test……………………………………………………………………………
Other Tests
Heat treatment………………………………………………………………………
Hydraulic test…………… Kg/cm²
Identification mark of Inspecting Authority/Well known tube maker …………………….
NOTE.- In addition, the following information in respect of the material shall be furnished in a tabular form in
conformity with the requirements of Regulation 4(c)(vi) or the note thereto, as the case may be.
This information may be given from the established test data or if the material is of standard
quality, an extract from the standard may be furnished instead.
Metal
temperature
250
275
300
325
350
375
400
425
450
C
Et
Sc
Sr
MAWP
Tensile strength at 20 C……………………………………………………
24
475
500
525
550
575
600
Where
Et
**Sc
=
Yield at temperature t (0.2% proof stress).
= Average stress to produce an elongation of 1%(creep) in 100,000 hours at the various
working metal temperatures.
**Sr
= Average and lowest stress to produce rupture in 100,000 hours at various working metal
temperatures.
MAWP = Maximum Allowable Working Pressure in Kg./cm²
Temperature range in the table may extend upto the limit of applicability of the material.
**The value of Sc and Sr need be furnished only in respect of tubes intended to be used for working
metal temperature above 454 C (850 F).
Certified that the particulars entered herein are correct. The particulars of fabricated component are
shown in drawing No. ..................
The tube has been designed and constructed to comply with the Indian Boiler Regulations for a
maximum working pressure of _____________ Kg/cm² and maximum temperature of ____________ºC and
satisfactorily withstood a water test of ____ Kg/cm² on the ___________ day of ____________ 20___, in the
presence of our responsible representative whose signature is appended hereunder.
Maker’s Representative
(Name and signature)
Maker ___________________
(Name and Signature)
We have satisfied ourselves that the ________ have been constructed in accordance with Indian Boiler
Regulations 1950. The tests conducted on the samples taken from the finished tubes have been witnessed by us
and the particulars entered herein are correct.
Name and signature of
Competent Person
Name and signature of
Inspecting Authority/Well Known Tube Maker
Place _______________
Date ________________
NOTE (1).- This form is intended for the use of both tube manufacturers and tube fabricators. Only such of
the columns or paragraphs that are applicable, or information that can be obtained and furnished
from other certificates, need be filled or entered in this form.
NOTE (2).- In the case of fabrications made from steel tubes obtained from elsewhere, particulars in regard to
the “material” and “Tubes” shall be taken from similar forms of certificates obtained in respect of
pipes and noted in the appropriate columns or paragraphs.
NOTE-(3).- For Stock and sale purpose, one Form shall be issued for not more than ten tubes.
In the case of tubes made from steel, made and tested by well-known Steel Makers in India or
other countries particulars regarding the ‘material’ as certified by them in Form IV shall be noted in
the appropriate columns or paragraphs of Raw material in this ‘certificate.”.
25
“FORM III-C
[See regulation 4(g)]
Certificate of Manufacture and test of Boiler Mountings and Fittings
Certificate No. …………..
Date:-----Name of part…
Quantity --------SL No …………………………………………………
Drawing No……………………………….
Maker’s name and address………………………………………………
Customer’s Name & Address……..
Design pressure……………....... .kg./cm2
Design temperature…………….. ºC
Metal
temperature
250
275
300
325
350
375
400
425
450
475
500
525
550
575
600
ºC
MAWP
MAWP = Maximum Allowable Working Pressure in Kg./cm²
Hydraulic test pressure………… .kg./cm2
Main dimensions……………………………………………………………………
Specification…………………………………………………………………
Inspecting Authority’s Identification Marks………………………………………
Chemical composition……………………………………………………………….
Physical test results………………………………………………………………….
(i)
tensile strength………………………………………………………
(ii)
transverse bend test………………………………………………….
(iii)
elongation……………………………………………………………
Other Tests…………………………………………………………………………..
RAW MATERIAL
Process of manufacture………………………………………………………………
Fully killed/rimmed……………………………………………………………
Specification……………………………………………………….
Heat Number…………………………………………………………..
Size……………………………………………………………………………………
Test Certificate No. & Date………………………………………....
Name of the Maker…………………………………………………………….
Name of Inspecting Authority……………………………………………………….
Certified that the particulars entered herein by us are correct.
The ___________ has been designed and constructed to comply with the Indian Boiler Regulations
1950 for a maximum working pressure of ____________ kg./cm2
and maximum temperature of ______ ºC and satisfactorily withstood a hydraulic test using water or kerosene or
any other suitable liquid to a pressure of ____________ kg./cm2 on the __________ day of ________________
20___ in the presence of our responsible representative whose signature is appended hereunder:
Maker Representative
(Name and signature)
MAKER________________
(Name and Signature)
26
We have satisfied ourselves and the _________ has been constructed and tested in accordance with the
requirements of the Indian Boiler Regulations, 1950. We further certify that the particulars entered herein are
correct.
Name and signature of
Competent Person
who witnessed the tests
Name and signature of
Inspecting Authority
Place _______________
Date ________________
Note:
(1)In the case of valve chest made and tested by well known Foundries or Forges recognized
by the Central Boilers Board in the manner as laid down in regulations 4A to 4H, particulars
regarding the material as certified by them, in Form III-F / Form III-G & Form IV, shall be
noted in the appropriate columns or paragraphs in the certificates and in case of certificates
from Well Known Foundries or Forges is produced, such certificate may be accepted in lieu of
the certificate from Inspecting Authority in so far as it relates to the testing of material
specified in the Form.
(2) In case of safety valves, details and test results as required in item No.8 of Form-III shall
also be furnished duly signed by manufacturer and inspecting authority.
(3) For Stock and sale purpose, one Form shall be issued for not more than fifty mountings
and fittings.”.
27
“FORM III-D (deleted)
&
FORM III-E (deleted)
28
“FORM III-F
(See regulations 73 to 80)
CERTIFICATE OF MANUFACTURE AND TEST OF CASTINGS
Certificate No. and date
Heat Number* and date of pouring
Maker’s name and address …….
Customer’s name and address …………………………………………………………
Drawing Nos. ……………………………………………………………………………………….
Description and quantity______________________________Sl.No. ___________________
Foundry identification__________________________________
Chemical composition
Heat treatment
Physical test results.
(i) Tensile strength
(ii) Transverse bend test
(iii) Elongation
(iv) Other tests
Certified that the particulars entered herein by us are correct. This satisfies the requirements of Indian
Boiler Regulations, 1950.
Maker’s Representative
(Name and signature)
Maker ___________________
(Name and Signature)
Name and signature of
Competent Person
Name and signature of
Inspecting Authority/Well Known foundry
*for castings of size more than 100mm Heat number must be as Cast.”.
29
“FORM III-G
(See regulations 81 to 85)
CERTIFICATE OF MANUFACTURE AND TEST OF FORGINGS
Certificate No. and date
Heat Number
Details of raw material
Maker’s name and address …….
Customer’s name and address …………………………………………………………
Drawing Nos. ……………………………………………………………………………………….
Description and quantity______________________________ Sl.No._____________________
Forge shop identification__________________________________
Chemical composition
Heat treatment
Physical test results.
(i) Tensile strength
(ii) Transverse bend test
(iii) Elongation
(iv) Other tests
Certified that the particulars entered herein by us are correct. This satisfies the requirements of Indian
Boiler Regulations, 1950.
Maker’s Representative
(Name and signature)
Name and signature of
Competent Person
Maker ___________________
(Name and Signature)
Name and signature of
Inspecting Authority/Well Known Forge.”.
30
“FORM III-H
(See regulation 4)
CERTIFICATE OF MANUFACTURE AND TEST FOR
(HEADERS,DESUPERHEATERS/ATTEMPERATOR,BLOWDOWNTANK,FEEDWA
TERTANKS, ACCUMULATOR, DEAERATOR)
T.C.NO.:
DATE :
Name of the Part
:
Maker's Name & Address
:
Customer's Name & Address
:
Drawing No.
:
Process of Manufacture,
Material condition,
chemical composition,
Tensile Strength,
Tolerances,
:
Design
(Kg/cm²)
Refer enclosed Raw
material Test Certificates
or Form IV-A in lieu of
Raw material Test
Certificates
Bend Test, Flattening Test
etc.
Pressure :
Design Temp.(ºC)
:
Heat Treatment
:
Hydraulic
Pressure
:
Test
Non-destructive
Testing
:
Inspecting Authority Identification Mark:
Item
No.
PART NAME
01
PIPE
02
END COVER
03
STUBS
04
BRANCH PIPES
MATERIAL
SIZE
QUANTITY
MELT No.
05
06
Certified that the particulars entered herein are correct.
The parts have been constructed to comply with the Indian Boiler Regulations for a working pressure of -------- and temperature of ----------and satisfactorily withstood a water test of -- on the -- day of -- in the
presence of our responsible representative whose signature is appended hereunder.
Final Inspection Date :
Signature and Seal of Maker's Representative
Signature and Seal of Maker
Final Inspection Date :
31
We have satisfied ourselves that the……… have been constructed in accordance with Indian Boiler
Regulations, 1950. The tests conducted have been witnessed by us, wherever applicable and the
particulars entered herein are correct.
Name and Signature of
Competent Person
Place
Date
Name and Signature of
Inspecting Authority
:
:.
32
“FORM III- I
( See regulation 4)
CERTIFICATE OF MANUFACTURE AND TEST FOR DISHED ENDS / END COVERS
T.C.NO.:
DATE :
Name of the Part
:
Maker's Name & Address
:
Customer's Name & Address
:
Drawing No.
:
Process of Manufacture,
Material condition, chemical
composition, Tensile
Strength, Tolerances,
Bend Test, Flattening Test
etc.
:
Design
(Kg./cm²)
Refer enclosed Raw
material Test Certificates
or Form IV-A in lieu of
Raw material Test
Certificates
Pressure :
Design Temp.(ºC)
:
Heat Treatment
:
Hydraulic
Pressure
:
Test
Non-destructive
Testing
:
Inspecting Authority Identification Mark:
ITEM
No.
PART NAME
01
PLATE / FORGING
MATERIAL
SIZE
QUANTITY
SPECN.
MELT No./
PLATE NO.
TC NO & DATE
Certified that the particulars entered herein are correct.
Signature and Seal of Maker's Representative
Signature and Seal of Maker
Final Inspection Date :
We have satisfied ourselves that the _____________have been constructed in accordance with the
Indian Boiler Regulations, 1950. The test conducted have been witnessed by us and the particulars
entered herein are correct.
Name and Signature of
Competent Pertson
Place
Date
Name and Signature of
Inspecting Authority
:
:”.
33
FORM IV
STEEL MAKER’S CERTIFICATE OF MANUFACTURE AND RESULTS OF TESTS
[Regulation 4(c)(iv) & 4(f)]
Designation of rolling mill ………………………………………………………………………
We hereby certify that the material described below has been made by M/s. ……………… by the
………………… process, as per specifications ………………… and rolled by ………………… and has been
satisfactorily tested in the presence of our Test House Manager or his representative in accordance with the
stipulated tests and tolerances.
For gothic bars/scalps, billets and hot rolled strips which are to be processed further by the same
manufacturer for making tubes/pipes, the physical properties are not required to be mentioned by the steel
manufacturer.
Signature or Initials
Test House Manager
Date
Date of tests …………… 20……
Ordered by ……………………...
……………………………
Boiler Number ………………….
Order Number
Remarks
Bend Tests
Elongation in
inches
Tensile breaking
strength in tons
per sq. in.
Number of pieces
Thickness or
diameter in
32nds in.
Breadth Ft. in.
Length Ft. in.
Size of plate and bar
Part of Boiler
Brand & Number
Charge Number
RESULTS OF TESTS
Chemical analysis…………………………………………………………………………………………………
Note: Where the steel is manufactured by a maker, who is not recognised as a Well-known Steel Maker, the certificate of
test shall be signed by the Inspecting Authority.
34
“FORM IV-A
[See regulation 4(c)(iv)]
CERTIFICATE OF MANUFACTURE AND RESULTS OF TESTS IN LIEU OF ORIGINAL
TEST CERTIFICATES
It is hereby certified that original Test Certificate contain the following information in respect of the material
used in the manufacture of the boiler or components thereof bearing Makers Number …………………………
according to Drawing Number :
Boiler component
Quantity size
Cast/Heat No.
Steel Making
Specification
Plate No.
Process
1
2
3
4
5
6
Name of Steel Maker/Part
Maker
Certificate No. & Date
Heat Treatment
7
8
9
% Chemical Analysis CMnPSSi* other
alloying elements
Yield strength
(Kg/mm2)
U.T.S.
(Kg/mm2)
Elongation %
Gauge Length
10
11
12
13
Bend Test Name of the
inspecting
authority
14
*(Carbon, Maganese, Phosphorus, Sulpher, Silicon).
Certified that the particulars entered herein by us are correct. This satisfies the requirements of Indian Boiler
Regulations, 1950.
Maker’s Representative
(Name and signature)
Maker ___________________
(Name and Signature)
Name and signature of
Competent Person
Name and signature of
Inspecting Authority”.
35
15
Counter foil
No.
………………………
………………………
are hereby permitted to use the ………… Boiler
(Registry No. ………) Boiler Rating …………
made by …………… and bearing Maker’s
number …………… at a maximum pressure of
……… lbs. per square inch pending the issue of or
refusal of a certificate within six months from the
date thereof after which period this order will
become void.
Date ……………
Inspector of Boilers
FORM V
[Regulation 381(c)]
PROVISIONAL ORDER UNDER SECTION 9 OF THE INDIAN
BOILERS ACT OF 1923
…………………………
are
hereby
permitted to use the ……………… Boiler
(Registry No. …………) Boiler Rating
…………… made by …………… and bearing
Maker’s number ……………… at a maximum
pressure of ……………… lbs. per square inch
pending the issue of or refusal of a certificate
within six months from the date thereof after
which period this order will become void.
Dated ……………
Inspector of Boilers
N.B.: This order must be produced on demand by any authorised
person and surrendered to Chief Inspector on receipt of
orders.
36
FORM VI
……………Boiler Inspection Department
CERTIFICATE FOR USE OF A BOILER
(Regulation 389)
Registry Number of Boiler
Type of Boiler
Boiler Rating
Place and year of manufacture
Maximum Continuous Evaporation
Name of Owner
Situation of Boiler
Repairs
Remarks
Hydraulically Tested on
to
lbs. per sq. inch
I hereby certify that the above described boiler is permitted by
me/the Chief Inspector under the provisions of Section 7/8 of the Indian Boilers
Act, No. V of 1923, to be worked at a maximum pressure of ……………… lbs.
to the square inch for the period from ……………… to ………………
The loading of the ……………… safety valve is not to exceed ………………
Fee Rs. ……………… paid on ………………
Dated at ………… this ………… day of ………… 20……
Competent Person
Countersigned
Chief Inspector
See Reverse for “Conditions”
CONDITIONS
(REVERSE OF FORM VI)
(1) No structural alteration, addition of renewal shall be made to the
boiler otherwise than in accordance with section 12 of the Act.
(2) Under the provisions of Section 8 of the Act this certificate shall cease to be in force:
(a) on the expiry of the period for which it was granted; or
(b) when any accident occurs to the boiler; or
(c) when the boiler is moved the boiler not being vertical boiler the heating
surface of which is less than two hundred square feet, or a portable or
vehicular boiler; or
(d) save as provided in section 12 of the Act, when any structural alteration,
addition or renewal is made in or to the boiler; or
(e) if the Chief Inspector in any particular case so directs when any structural
alteration, addition or renewal is made in or to any steam-pipe attached to the
boiler; or
(f) on the communication to the owner of the boiler of an order of the Chief
37
Inspector or Inspector prohibiting its use on the ground that it or any boiler
component attached thereto is in a dangerous condition.
Under Section 10 of the Act, when the period of a certificate relating to a boiler has expired, the owner shall,
provided that he has applied before the expiry of that period for a renewal of the certificate be entitled to use the
boiler at the maximum pressure entered in the former certificate, pending the issue of orders on the application
but this shall not be deemed to authorise the use of a boiler in any of the cases referred to in clauses (b), (c), (d),
(e) and (f) of sub-section (1) of section 8 occurring after the expiry of the period of the certificate.
(3) The boiler shall not be used at a pressure greater than the pressure entered in the certificate as the maximum
pressure nor with the safety valve set to a pressure exceeding such maximum pressure.
(4) The boiler shall not be used otherwise than in a condition which the owner reasonably believes to be
compatible with safe working.
Note: The particulars and dimensions regarding this boiler may be obtained by the owner on payment in the
prescribed manner on application to the Chief Inspector.
38
FORM VII
INSPECTING AUTHORITY’S CERTIFICATE OF INSPECTION UNDER CONSTRUCTION
DESIGNATION OF INSPECTION AUTHORITY
[Regulation 501(e)]
We hereby certify that ……………… type, ……………… Economiser, consisting of ……………… sections
and tubes to each section was constructed for a working pressure of ……………… lbs. Messrs ………………
under our supervision and inspected at various stages of construction by the Competent Person and that the
construction and workmanship were satisfactory and in accordance with the standard conditions for the design
and construction of Economiser laid down in Chapter XI of the Indian Boiler Regulations, 1950.
Identification Mark on each section.
Branch Pipe on other pressure part.
Position of same.
The sections on completion were subjected to a water pressure of ……………… lbs. per sq. in. for ten minutes
in the presence of the Competent Person on ……………… and satisfactorily withstood the test in accordance
with Reg. 504.
Samples of the material used in the constructions of the Economiser were tested in the presence of the
Competent Person and were found to comply with the tests prescribed in Chapter XI of the Indian Boiler
Regulations, 1950.
We have satisfied ourselves that the construction and dimensions of the Economiser are as shown in the Maker’s
Drawing No. ……………… signed by us and that the particulars entered in the maker’s certificate of
manufacture in Form VIII countersigned by us are correct to the best of our knowledge and belief.
Dated at …………… this …………… day of …………… 20……
Signature of Inspecting Authority
39
FORM VIII
WORKS ADDRESS
1. Description
2. Inspecting
Authority
3. Construction and
Workmanship
Constructor’s Certificate of Manufacture and Test
[Regulation 501(D)]
Type of Economiser
No. of tubes
No. of Sections
lbs.
Intended working pressure
Total heating
Year of manufacture
Surface of tubes
Description
Economiser constructed under supervision of ………………………………..
Sections hydraulically tested for ……… minutes and inspected after test by ……
Details are in Drawing No. ………………………………
All castings are well finished free from external defects, porous places and blow-holes and true to
dimensions without warping.
Where chapters are used, there is satisfactory fusion with the metal.
Chapters properly tinned with metal free from lead.
All screw threads are of Whitworth form.
All components parts are
interchangeability throughout.
4. Economisers and
fittings
Parts
Particulars of
material used
Headers Tubes
and/or Pipes Valve
Chest Bolt
manufactured
Material
to
limit
Maker
gauges
to
secure
Inspecting Officer
Remarks
THICKNESS OF PARTS AND TENSILE TEST—LIMIT
5. Part of Economiser
Thickness in
32nds
Tensile strength limits
to tons
Elongation limits Gauge Length Brand and
to %
No.
Headers
Tubes
Bolts
Certified that the particulars entered herein are correct and that the parts and fittings
mentioned above have been used in the construction and fittings of the Economiser.
The particulars shown against the various parts used are in accordance with the Maker’s certificates in our
possession.
The design of the economiser in section and end view with principal parts fully dimensioned is that shown in
Drawing No. ………… The Economiser has been designed and constructed to comply with the Indian Boiler
Regulations for a working pressure of ………… lbs. per sq. in. at our Works Regulations for a working pressure
of ………… lbs. per sq. in. at our Works above-mentioned and the sections satisfactorily withstood a water test
of ………… lbs. per sq. in. for ………… minutes on ………… day of …………20…… in the presence of our
…………responsible representative whose signature is appended hereunder.
Signature of Engineer who witnessed the test
Designation of Maker
Dated at ……… this ……… day of ……… 20……
Signature of Inspecting Authority
Note: The drawing of the Economiser and Maker’s certificate of manufacture showing results of tests for
tensile strength and elongation must accompany this certificate and if the economiser has been built
under the supervision of an Inspecting Authority their certificate in Form VII must accompany.
————————————————————————————————————————————-40
FORM IX
(Regulation 528)
INDIAN BOILERS ACT, 1923
BOILERS INSPECTION
DEPARTMENT
ECONOMISERS
REGISTRY NUMBER
—————————————————————————————————————————————
MEMORANDUM OF INSPECTION
OR
REGISTRATION BOOK
41
MISCELLANEOUS
District ………………………………………………………..
Owners ……………………………………………………….
Address of Factory ………………………………………….
Nearest Railway Station ……………………………………
Economiser Registered at ………………………………….
Register Book No …………………………………………...
Registry Number …………………………………………….
Approved Working Pressure ……………………………….
Economiser Rating ………………………………………….
Registration Book filled at ………………………………….
Remarks on transfer etc. …………………………………..
…………………………………………………………………
on ………………………………………………
Page …………………………………………...
Verified on …………………………………….
lbs ………………………………………………
Inspection fee …………………………………
on ………………………………………………
PROVISIONAL ORDER AND CERTIFICATE RECORD
Fee
Date of
payment
Date of
Inspection
Certificate
No. and Date
Type
of
………………………………………...
Period of
Certificate
Working
pressure
Economiser
Rating
Remarks and
Inspector’s initial
Economiser
Maker …………………………………………………………
Intended Working Pressure ………………………………..
Place and year of make …………………………………….
Maker’s No …………………………………………………..
Description of Economiser …………………………………
No. of tubes …………………………………………………. length …………………… Dia. ………………
Thickness …………………………………………………….
Internal dimensions …………………………………………
No. of Headers ………………………………………………
Thickness of Headers ………………………………………
Length of Top Branch Pipe ………………………………...
Length of Bottom Branch Pipe …………………………….
Dimensions of cap openings ………………………………
Diameter of cap bolts ……………………………………….
Thickness ……………………………………..
Thickness ……………………………………..
MOUNTINGS
No.
Diameter
42
Type
Position
Material
Relief
………………………………………………….
Valve
Stop Valve …………………………………………………...
Blow Down …………………………………………………..
Thermometers ……………………………………………….
Pressure Gauge …………………………………………….
Additional Fittings …………………………………………….
MAKER’S CERTIFICATE
Name
of
Maker
………………………………………………………
……………
Maker’s Hydraulic Test Pressure
……………………………………………………………
………
Maker’s Drawing No.
……………………………………………………………
………
Name of Inspecting Authority
……………………………………………………………
………
Name of Maker of Material
……………………………………………………………
………
Tubes
…………………………………………
………..
Process
Headers
…………………………………………………..
Bolts
…………………………………………
………..
Test Results
Tubes
T
E
Headers
Pipes
Bolts
T
E
T
E
T
% Sulphur
% Phosphorus
Maker’s Identification Mark
Position
CALCULATIONS
HEADERS
TUBES
BRANCH PIPES
BOLTS
43
HEATING SURFACE
Total Heating Surface ………………………………………
Economiser Ratings ………………………………………..
Calculations made by ……………………………………… submitted on …………………………………..
on ………………………………………………
lbs. ……………………………………………..
lbs. ……………………………………………..
Calculations checked by ……………………………………
Least pressure, that for …………………………………….
Approved working pressure ………………………………..
Chief Inspector’s remarks and signature …………………
INSPECTOR’S NOTES
44
FORM X
[Regulation 525(e)]
Counterfoil
No.
Name of the person or firm to which
Provisional Order is granted.
Description of Economiser
Maker’s No.
Rating
Pressure permitted
Period
Date
Inspector
No.
Provisional Order under the Indian Boilers Act, 1923
——————————————————————————
are hereby permitted to use the Economiser Ry. No. ………… and …………
Economiser Rating ………… made by ………… and bearing Maker’s No.
………… at a maximum pressure of ………… lbs. per sq. in/maximum
temperature of ………… °F pending the issue or refusal of a certificate within
six months from the date thereof after which period this order will become
void.
Dated at ……… this ……… day of ……… 19……
Inspector
45
FORM XI
…………Boiler Inspection Department
CERTIFICATE FOR THE USE OF AN ECONOMISER
(Regulation 530)
Type
Registry Number of Economiser
No. of tubes
Number of Headers
Economiser Rating
Place and year of manufacture
Name of owner
Situation of Economiser
Repairs
Remarks
kg. per sq. cm.
to lbs. per sq. in.
Hydraulically tested on
I/We hereby certify that the above described Economiser is permitted by me/Chief
Inspector under the provisions of Section …………… of the Indian Boilers Act, 1923 (V of
1923) to be worked at a maximum pressure …………… lbs. per sq. in./maximum
temperature of °F or the period from ……………to …………….
This loading of the safety valve is not exceed, …………… lbs.
Fee Rs. …………… paid on ……………
Dated at ……………
This ………… day of ………… 20……,
Countersigned
Competent Person
Chief Inspector
CONDITIONS
(REVERSE OF FORM XI)
(1) No structural alteration, addition or renewal shall be made to the Economiser without a
written permission from the Chief Inspector.
(2) This certificate shall cease to be in force—
(a) on the expiry of the period for which it was granted, or
(b) when any accident occurs to the Economiser, or
(c) when any structural alteration, addition or renewal is made in or to the
Economiser, or
(d) save as provided in section 12 of the Act, when any structural alteration,
addition or renewal is made in or to the Economiser; or
(e) on the communication to the owner of the Economiser of an order of the Chief
Inspector or Inspector prohibiting its use on the ground that it is in a
dangerous conditions.
46
(3) The Economiser shall not be used at a pressure greater than the pressure/temperature entered in the certificate
as maximum pressure/temperature not with the relief valve set to pressure/temperature exceeding such
maximum pressure/temperature.
(4) The Economiser shall not be used otherwise than in a condition which the owner reasonably believes to be
compatible with safe working.
N.B. : Details regarding this Economiser are recorded in a Registration Book No. ………… of which a copy
may be obtained on payment on application to the Chief Inspector.
47
FORM XII
(Regulation 613)
Record of Welder’s Qualifications/Requalifications Tests (Indian Boiler Regulations,
1950)
Place of Test ………………
Date ………………………...
Name of Welder ……………………………………………………………………………………………………
Father’s name ………………………………………………………………………………………………………
Date of Birth ………………………………………………………………………………………………………..
Address ……………………………………………………………………………………………………………..
..……………………………………………………………………………………………………………………
…
Service of experience on Gas/Electric Arc ……………………………… years……………………………....
Signature of Welder ………………………………………………………..………………………………………
Names and addresses of the firms where trained ……………………………………………………………...
..……………………………………………………………………………………………………………………
…
Tested on ……………………………………………………………………………………... (Plate, pipe, tube)
Gas of electric A.C./D.C. …………………………………………………..………………………………………
Kind of test ……………………………………….……………………………………… (Groove/Gillet/Branch)
Position
..…………………………………………………………………………………………………………….
Thickness of material used ………………………………………………………………………………………..
Diameter and thickness of pipe, branch or tubes used ……………………………………………………….
Quality of base material and electrode or filler rod ……………………………………………………………..
RESULTS OF OBSERVATIONS
Marks
Maximum
A. Procedure
1. Preparation of specimen
3
2. Size & Grade of electrode or filler rod
2
3. Number of runs and manipulation of control
5
B. Visual Inspection
4. Root penetration
10
5. Freedom from undercut
5
6. Disposition of runs
2
7. Uniformity of surface
1
8. Shape of profile
1
9. Smoothness of joints
2
10. Freedom from cavities & slags
5
11. Dimensions of weld deposit
1
48
Awarded
3
12. Quality of weld metal (Overheating, surface cracks, spongy surface
etc.)
C. Physical Test
13. Face bend test
10
14. Root bend test
20
D. Etch Test
15. Disposition of runs
2
16. Degree of fusion
5
17. Root Penetration
11
18. Slags inclusions and porosity
5
E. Fractured Surface
19. Quality of weld metal (Excessive oxidation,
overheating, roughness, porosity, appearance).
7
carburisation,
100
Signature of Competent Authority
Observation
on
radiographic
……………………………………………………..
examination
(if
conducted)
Marks awarded …………………………………………………………………………………………………. %
Results of Oral or Written examination ………………………………………………………………………….
Marks awarded …………………………………………………………………………………………………. %
GENERAL REMARKS OF COMPETENT AUTHORITY ………………………………………………………
TYPE AND CLASS OF WELDING QUALIFIED …………………………… in Gas or Electric Arc welding.
PERIOD OF VALIDITY OF CERTIFICATE ……………………………… From …………… To ……………
Place ……………
Date …………….
Competent Authority
49
FORM XIII
QUALIFIED BOILER WELDER’S CERTIFICATE ISSUED UNDER THE INDIAN BOILER
REGULATIONS, 1950
Name of Welder ……………………………….
Father’s Name …………………………………
Date of Birth ………………………………
(SEAL) and
Signature of
Competent
Authority
PHOTO
Passport Size
Identification marks ……………………………
Left Hand Thumb Impression …………………..
Signature of Welder ……………………………..
Address of Welder ……………………………….
Period of Validity
From
…………………
…………………
…………………
…………………
To
…………………
…………………
…………………
…………………
This is to certify that Shri ……………… son of Shri ……………… has been examined and tested in
the prescribed manner in the presence of ……………… (Representative of Competent Authority) and is deemed
to have satisfactorily proved his ability to make sound welds as per particulars given below and is hereby
authorised to undertake such welds. He is authorised/not authorised to undertake welding where radiographic
examination is necessary under the Regulations.
Granted this …………… day of …………… 20…… under the seal and authority of ………………..
Representative of Competent Authority
SEAL
*Particulars :—
*Particulars shall contain information on the following:
Tested on
position
Plate/Pipe/Tube
Date
Material
Process
Class of welding
Backing strip
Electrode
Filter rod
Test piece X-rayed or not.
Period of Validity
From
…………………
…………………
…………………
…………………
with
Mild Steel or alloy steel
Class (Carbon or alloy steel)
Type
To
…………………
…………………
…………………
…………………
EMPLOYMENT PARTICULARS
From
To
Name of employer
50
Work on which engaged
Signature of employer
(COVER PAGE)
FORM XIV
[Regulation 394(C)]
INDIAN BOILERS ACT, 1923
Boiler Inspection Department
Steam Pipes and Connected Fittings
Identification Number
————————————————————————————————————————————--
Memorandum of Inspection Book
————————————————————————————————————————-MISCELLANEOUS
District
……………………………………………………………………………………………………………….
Owner ……………………………………………………………………………………………………………….
Address ……………………………………………………………………………………………………………..
Work of Factory : …………………………………………………………………………………………………..
Registration Number of Boilers to which the pipes and fittings, particulars of which are given in this
Memorandum are connected.
Remarks
Date
Particulars of additions & alterations
……………………
…………………………………………………………………………………………….
……………………
…………………………………………………………………………………………….
……………………
…………………………………………………………………………………………….
……………………
…………………………………………………………………………………………….
PLAN OF STEAM PIPES & THEIR CONNECTED FITTINGS
51
FEE AND APPROVAL TO PLAN RECORD
Drawing
No.
Total length
of Steam
Pipes
No. of
Connected
vessels
Fee
Date of
Payment
No. & date of
approval of
Plan & Layout
W.P.
approval
Kg/cm2
Temp
allowed
ºC
Remarks &
initial of
Inspector
STEAM PIPES—PARTICULARS AND DIMENSIONS
Situation …………………………………………………………………………………………………………….
Ry. No. of connected Boilers ……………………………………………………………………………………..
Steam Piping System include …………………………………………………………………………………….
Pipes Material ………………………………………… Diameter (outside) …………………………………….
Pipes Thickness ……………………………………… Make ……………………………………………………
Attachment of Flanges …………………………………………………………………………………………….
Elbows, Tees etc. …………………………………………………………………………………………………..
……………………………………………………………………………………………………………………….
.
Support
………………………………………………………………………………………………………………
Flexibility
…………………………………………………………………………………………………………….
Drainage …………………………………………………………………………………………………………….
Feed
pipes
………………………………………………………………………………………………………….
Outside
Dia.
……………………………………………
……………………………………………..
Thickness
Make
…………………………………………………………………………………………………………………
Max. Pressure ………………………………………… Max. Temp …………………………………………….
Connected Vessel ………………………………………………………………………………………………….
No.
…………………………………………………………………………………………………………………...
Type
………………………………………………………………………………………………………………….
Max. Design Press …………………………………… Max. Design Temp. …………………………………...
Date of Installation …………………………………………………………………………………………………
First Inspection inside & …………………………………………………………………………………………..
Outside
………………………………………………………………………………………………………………
Feed Pipes Hydraulic Test to …………… kg/cm2 …………… By ……………… on
……………………….
Remarks …………………………………………………………………………………………………………….
CALCULATIONS
Steam Pipes :
………………………………………………………………………………………………………
……………………………………………………………………………………………………………………….
.
52
……………………………………………………………………………………………………………………….
.
……………………………………………………………………………………………………………………….
.
CALCULATIONS
Steam Pipes :
………………………………………………………………………………………………………
……………………………………………………………………………………………………………………….
.
……………………………………………………………………………………………………………………….
.
……………………………………………………………………………………………………………………….
.
CALCULATIONS
Steam Pipes :
………………………………………………………………………………………………………
……………………………………………………………………………………………………………………….
.
……………………………………………………………………………………………………………………….
.
……………………………………………………………………………………………………………………….
.
CALCULATIONS
……………………………………………………………………………………………………………………….
.
……………………………………………………………………………………………………………………….
.
……………………………………………………………………………………………………………………….
.
……………………………………………………………………………………………………
…………………..
INSPECTOR’S NOTE
……………………………………………………………………………………………………………………….
.
……………………………………………………………………………………………………………………….
.
……………………………………………………………………………………………………………………….
.
……………………………………………………………………………………………………
…………………..
53
“FORM XV-A
[See regulation 4 A (2)]
QUESTIONNAIRE TO BE ANSWERED BY FIRMS/COMPANIES SEEKING
RECOGNITION BY THE CENTRAL BOILERS BOARD TO BECOME AN
“INSPECTING AUTHORITY”
1.
The registered name and address of the company/firm:
2.
Address for correspondence:
3.
The year in which the company/firm was established.
4.
Proposed countries/areas of operation as Inspecting Authority:
5.
Is company/firm registered in the proposed countries of operations?
If so, please give details thereof.
6.
Have you any Branch or Associate Office?
If so, please give their names and addresses.
7.
Is company/firm functioning as an Inspecting Authority under the Indian or
International codes and standards?
If so, details thereof.
8.
In case of renewal of recognition as Inspecting Authority under the Indian Boiler
Regulations, 1950, had you conducted inspection during the last five years?
If yes, details thereof.
9.
Is company/firm involved in any commercial activity
other than inspection,
certification and related activities under the Indian or International Codes and
standards?
If so, details thereof.
54
10.
Please state the types, size and the range of working pressure of the boilers which you
have so far inspected during manufacture as an Inspecting Authority, also state the
classes of service you render, namely:(a) Please name the various stages of manufacture at which inspections are carried
out.
(b) Only hydraulic test after the manufacture of the boiler.
11.
How many Inspectors/Competent persons have you in your employment? Please give
details of the qualifications held by those persons.
12.
Have you any Testing Laboratory of your own to conduct all destructive and nondestructive tests required in connection with the manufacture of boilers?
If so, details thereof.
13.
Have you in-house design and drawing inspection office?
If so, details thereof.
14.
Have you any documented quality programme established and maintained to fulfill the
inspection requirements as per Indian Boiler Regulations, 1950?
If so, details thereof.
15.
Are you having Curriculum Vitae of all the inspectors/competent persons employed in
the organization for inspection and certification work?
16.
Are you having a training programme for Inspectors/Competent persons?
If so, details thereof.
17.
Are you prepared to conduct the work of Inspection of boilers, economisers and their
accessories strictly in conformity with the Indian Boiler Regulations, 1950?
55
18.
Are you prepared to accept full responsibility for the certificate issued by you?
19.
Has your request for recognition as an Inspecting Authority been rejected by any
Authority? If so, please give details.
20.
Are you prepared to issue certificates for the products, you inspect, in the formats of
the Indian Boiler Regulations?
21.
Are you aware that the recognition is for a period of five years only, which is
renewable after every five years on fresh assessment?
SIGNATURE & SEAL
56
FORM XV-B
[See regulation 4 A (2)]
QUESTIONNAIRE FOR ELICITING INFORMATION REGARDING THE
COMPETENCY OF A FIRM/COMPANY TO BE RECOGNISED AS
“COMPETENT AUTHORITY”
1.
Registered name and address of the company/firm.
2.
Address for correspondence.
3.
Year in which the company/firm was established.
4.
Address of branch or associate office, if any.
5.
Principal work of the company/firm.
6.
Does the company/firm have any training section for the welders? If so, details of the
scheme to be stated.
7.
Does the company/firm regularly conduct tests on welds done by its welders? If so,
the code followed and the details of tests carried out may please be stated.
8.
What are the facilities that can be provided or availed of by the organisation for
conducting the tests?
9.
Is the company/firm prepared to undertake testing of welders employed by other
organisation?
10.
In case of renewal of recognition as Competent Authority under the Indian Boiler
Regulations, 1950, have you undertaken inspection and certification of welders during
the last five years?
If yes, details thereof.
57
11.
Whether the company/firm is prepared to conduct tests as per requirements of the
Indian Boiler Regulations, 1950?
12.
The amount of fee which the company/firm would charge from a candidate for
conducting a test for the issue of certificate. Estimates under the following heads may
be given:
(a) For the supply of tests pieces, electrodes and/or filler rods:
(b) For the use of welding machine:
(c) For machining the test pieces and preparation of specimen:
(d) For conducting mechanical tests (including specimen preparation):
(e) For non-destructive testing:
13.
Is the company/firm prepared to examine and issue certificate to welders in
accordance with the requirements of the Indian Boiler Regulations, 1950?
14.
Is the company/firm prepared to take full responsibility for certificates issued by it.
15.
Are you aware that the recognition is for a period of five years only which is
renewable after every five years on fresh assessment?
SIGNATURE & SEAL
58
FORM XV-C
[See regulation 4A (2)]
QUESTIONNAIRE TO BE ANSWERED BY STEEL MAKER SEEKING
RECOGNITION BY CENTRAL BOILERS BOARD TO BE NOTIFIED AS
“WELL KNOWN STEEL MAKERS”
1.
Registered Name and address of the firm/company:
2.
Works address:
3.
The year in which the factory was established:
4.
Capacity for production of steel:
5.
Process of manufacture of steel:
6.
Variety of steel products:
7.
Range of steel produced in each variety:
8.
Various national and international Standards to which the steel products are
manufactured:
9.
Testing facilities available within the works:
10.
Types of tests conducted:
11.
If so, by whom conducted:
12.
Are the tests conducted by the firm/company acceptable to the other organisations of
the country? If so, by whom?
13.
Is the firm/company prepared to conduct tests in accordance with the Indian Boiler
Regulations, 1950?
14.
Is the firm/company recognised as “Well Known Steel Maker” in any other country?
15.
Whether the firm/company has any previous experience to produce steel in
accordance with the provision of Indian Boiler Regulations, 1950 under the inspection
of any recognised Inspecting Authority.
If yes, details thereof.
59
16.
Whether the firm/company is prepared to furnish certificates under the provision of
Indian Boiler Regulations, 1950.
17.
In case of renewal of recognition, had you manufactured and supplied steel as “Well
Known Steel Maker” under the Indian Boiler Regulations, 1950 during the last five
years?
If yes, details thereof.
18.
Whether the firm/company manufacture steel from the ore itself or from ore and scrap
or scrap only:
19.
Whether the firm is agreeable to show their manufacturing process and in-house
testing facilities to a team consisting of three members appointed by the Board.
20.
Are you aware that the recognition is for a period of five years only which is
renewable after every five years on fresh assessment?
SIGNATURE & SEAL
60
FORM XV-D
[See regulation 4A (2)]
QUESTIONNAIRE TO BE ANSWERED BY FOUNDRY/FORGE SEEKING
RECOGNITION BY CENTRAL BOILERS BOARD TO BE NOTIFIED AS
“WELL KNOWN FOUNDRY/FORGE”
1.
The registered name and address of the firm/company:
2.
Works address:
3.
The year in which the factory was established:
4.
Capacity of the foundry/forge:
5.
(i) Capacity for production of forgings/castings:
(ii) Maximum weight and size of forgings/castings:
6.
Detailed description of the type of job done by the firm/company:
7.
Materials of castings/forgings (ferrous-plain or alloy steel, non-ferrous alloys):
8.
Range of forgings/casting produced in each variety:
9.
Testing facilities available within the works:
10.
Details of testing facility, namely chemical and physical tests:
11.
Types of test conducted:
12.
If so, by whom conducted?
13.
Are the tests conducted by the firm/company itself acceptable to the other
organisations of the country? If so by whom?
14.
Is the firm/company prepared to conduct tests in accordance with the Indian Boiler
Regulations, 1950?
15.
Is the firm/company recognised as “Well Known Foundry/Forge” in any other
country?
61
16.
Whether the firm/company is in a position to produce forgings/casting in accordance
with any national/international specifications fulfilling the minimum requirements of
Indian Boiler Regulations, 1950:
17.
Whether the firm/company has any previous experience to produce forgings/castings
in accordance with the provision of Indian Boiler Regulations, 1950 under the
inspection of any recognised Inspecting Authority.
If yes, details thereof.
18.
Whether the firm/company is prepared to furnish certificates under the provision of
Indian Boiler Regulations, 1950.
19.
In case of renewal of recognition, had you manufactured and supplied
castings/forgings as “Well Known Foundry/Forge” under the Indian Boiler
Regulations, 1950 during the last five years?
If yes, details thereof.
20.
Whether the firm/company is agreeable to show their process of manufacture, inhouse testing facilities to a team of members appointed by Central Boilers Board.
21.
Are you aware that the recognition is for a period of five years only, which is
renewable after every five years on fresh assessment?
SIGNATURE & SEAL
62
FORM XV-E
[See regulation 4A (2)]
QUESTIONNAIRE TO BE ANSWERED BY TUBE/PIPE MAKER SEEKING
RECOGNITION BY CENTRAL BOILERS BOARD AS
“WELL KNOWN TUBE/PIPE MAKER”
1.
Registered name and address of the firm/company:
2.
Works address:
3.
The year in which the factory was established:
4.
Capacity of production of Tube/Pipe and the tonnage details per during the
last three years:
5.
Steel grades of Tube/Pipes under production:
6.
Size range of Tubes/Pipes under production:
7.
Process of manufacture of Tube/Pipes:
8.
(a) Whether the firm/company is producing the raw material or purchasing
the raw material.
(b) If the raw material is purchased, give the details of purchase in last three
years.
(i) from well known steel makers under Indian Boiler Regulations, 1950.
(ii) from other sources.
9.
If purchase is as per 8(b)(ii), state whether the raw material is tested at Tube
maker’s/Pipe maker’s premises under Indian Boiler Regulations, 1950.
10.
If the firm/company is producing raw material, state whether the
firm/company is recognised as Well Known steel maker under Indian Boiler
Regulations, 1950.
11.
Major manufacturing facilities available with the firm/company:
12.
Testing facilities available with the works:
13.
Types of tests conducted on Tubes/Pipes (enclose complete quality control
plan from raw material stage to finished stage along with the quality control
and inspection personnel of the firm):
63
14.
The details of failures and rejection
(a) By Non-Destructive Testing(NDT)
(b) By Destructive Testing.
15.
Whether the firm/company is in a position to manufacture Tubes/Pipes and
also provide for their necessary testing facilities in accordance with the
provision in Indian Boiler Regulations, 1950.
16.
Whether the firm/company has any previous experience to produce Tubes/
Pipes in accordance with the provision of Indian Boiler Regulations, 1950
under the inspection of any recognised Inspecting Authority.
If yes, details thereof.
17.
Whether the firm/company is prepared to furnish certificates under the
provision of Indian Boiler Regulations, 1950.
18.
In case of renewal of recognition, had you manufactured and supplied Tubes/
Pipes as “Well Known Tubes/Pipes Maker” under the Indian Boiler
Regulations, 1950 during the last five years?
If yes, details thereof.
19.
The name of the firms to whom the firm /company has supplied
Tubes/Pipes:
20.
Whether the firm/company is agreeable to show their manufacturing process
and in- house facilities to a team consisting of three members appointed by
the
21.
Board.
Whether the firm/ company is aware of the fact that the recognition is for a
period of
five years only, which is renewable after every five years term
on fresh assessment?
SIGNATURE & SEAL
64
FORM XV-F
[See regulation 4A (2)]
QUESTIONNAIRE TO BE ANSWERED BY A LABORATORY SEEKING
RECOGNITION BY CENTRAL BOILERS BOARD AS A
“WELL-KNOWN MATERIAL TESTING LABORATORY”
1.
The registered name and address of the laboratory:
2.
Address of the laboratory:
3.
The year in which the laboratory was established:
4.
(a) Whether the laboratory is recognised by the Central Government or by a State
Government:
(b) If so, please furnish particulars of recognition:
5.
Name and address of branch or associate laboratory, if any:
6.
How long the laboratory has been functioning for testing of the products?
7.
Equipment or machines available in the laboratory for carrying out the non-destructive
or destructive testing:
8.
Type and range of tests carried out by the laboratory:
9.
Details of testing personnel and their qualifications or experience:
10.
Are you prepared to conduct the testing of specimens strictly as per the requirements
of the Indian Boiler Regulations, 1950?
11.
Has your request for recognition as an approved laboratory been rejected by any
authority? If so, please give details.
12.
Are you prepared to issue the certificates for the products you test in the formats of the
Indian Boiler Regulations, 1950?
65
13.
Whether you have any previous experience of conducting tests in accordance with the
provision of Indian Boiler Regulations, 1950 under the inspection of any recognised
Inspecting Authority.
If yes, details thereof.
14.
In case of renewal of recognition, had you conducted tests under the provisions of
Indian Boiler Regulations, 1950 during the last five years?
If yes, details thereof.
15.
Are you agreeable to show your laboratory and in- house
facilities
to
a
team
consisting of three members appointed by the Board?
16.
Are you aware that the recognition is valid for a period of five years only, which is
renewable for five years on fresh assessment?.
SIGNATURE & SEAL
66
FORM XV-G
[See regulation 4A (2)]
QUESTIONNAIRE TO BE ANSWERED BY A FIRM SEEKING RECOGNITION BY
CENTRAL BOILERS BOARD AS “REMNANT LIFE ASSESSMENT ORGANISTION”
UNDER REGULATION 391A
1.
The registered name and address of the firm/company
:
2.
Address of the firm /company
:
3.
The year in which the firm /company was established
:
4. (a)
Whether the firm/company is recognised by the Central
(b)
5.
Government or by State Government
:
If so, furnish particulars of recognition
:
Name and address of branch or associate firm,
if any
6.
:
How long your firm has been functioning for
Remnant Life Assessment of Boilers and Boiler
Parts
7.
:
Equipment or machines available in the
laboratory for carrying out the non-destructive
or destructive testing
8.
:
Type and range of tests carried out by the firm/company:
67
9.
Details of testing personnel and their qualifications
and experience
10.
:
Are you prepared to conduct the testing of
specimens strictly as per the requirements
of the Indian Boiler Regulations, 1950?
11.
:
Has your request for recognition as an approved
organisation been rejected by any authority?
If so, please give details.
12.
:
Are you prepared to issue the certificates for
the tests recommended in the formats of the
Indian Boiler Regulations, 1950?
13.
In case of renewal of recognition, had you
conducted Remnant Life Assessment of Boilers
and Boiler parts under the Indian Boiler
Regulations, 1950 during the last five years?
If yes, details thereof.
14.
Are you agreeable to show your laboratory and in-house
facilities to a team consisting of three members appointed by the Board?
15.
Are you aware that the recognition is valid for a period
of five years only, which is renewable for five years on fresh assessment.
SIGNATURE & SEAL”.
68
“FORM XVI-A
[See regulation 4C (2)]
National Emblem
Serial No.
File No.
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR INSPECTING AUTHORITY
This is to certify that the Inspection and Quality Management System of:
M/s
________________________________
________________________________
________________________________
_________________________________
has been evaluated by the Central Boilers Board and has been granted recognition under
regulation 4C(2) of the Indian Boiler Regulations, 1950, as an INSPECTING AUTHORITY for
operation in
__________________________________________________________________
This certificate is valid for five years, i.e. upto…………………………..
__________________________________________________________________
Validity is subject to the adherence to the quality Control prescribed under the provisions of the
Indian Boiler Regulations, 1950.
_________________
Date of Issue
Certificate No._____
_________________
Secretary
69
FORM XVI-B
[See regulation 4C (2)]
National Emblem
Serial No.
File No.
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR COMPETENT AUTHORITY
This is to certify that the Examination of Welder System of:
M/s
_______________________
_______________________
_______________________
_______________________
has been evaluated by the Central Boilers Board and has been granted recognition under
regulation 4C(2) of the Indian Boiler Regulations, 1950, as a COMPETENT AUTHORITY for
operation in
_____________________________________ _____________________________
This certificate is valid for five years, i.e. upto………………………..
__________________________________________________________________
Validity is subject to the adherence to the quality Control prescribed under the provisions of the
Indian Boiler Regulations, 1950.
_________________
Date of Issue
Certificate No.___________
_________________
Secretary
70
FORM XVI-C
[See regulation 4C (2)]
National Emblem
Serial No.
File No.
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR WELL-KNOWN STEEL MAKER
This is to certify that the Inspection and Quality Management System of:
M/s
_________________________
_________________________
_________________________
_________________________
has been evaluated by the Central Boilers Board and has been granted recognition under
regulation 4C(2) of the Indian Boiler Regulations, 1950, as WELL KNOWN STEEL MAKER,
for the manufacture of _________________________________
__________________________________________________________________
for their factory at________________________________
________________________________
_________________________________
_________________________________
This certificate is valid for five years, i.e. upto_______________________
Validity is subject to the adherence to the quality control prescribed under the provisions of the
Indian Boiler Regulations, 1950.
_________________
Date of Issue
Certificate No.____________
__________________
Secretary
71
FORM XVI-D
[See regulation 4C (2)]
National Emblem
Serial No.
File No
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR WELL-KNOWN FOUNDRY
This is to certify that the Inspection and Quality Management System of:
M/s.
_______________________
_______________________
_______________________
has been evaluated by the Central Boilers Board and has been granted recognition under
regulation 4C (2) of the Indian Boiler Regulations, 1950 as a WELL KNOWN FOUNDRY for
the manufacture of
__________________________________________________________________
for their factory at________________________________
________________________________
_________________________________
_________________________________
This certificate is valid for five years, i.e. upto_______________________
Validity is subject to the adherence to the quality control prescribed under the provisions of the
Indian Boiler Regulations, 1950.
_________________
Date of Issue
Certificate No.____________
__________________
Secretary
72
FORM XVI-E
[See regulation 4C (2)]
National Emblem
Serial No.
File No
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR WELL KNOWN FORGE
This is to certify that the Inspection and Quality Management System of:
M/s
__________________________
__________________________
__________________________
has been evaluated by the Central Boilers Board and has been granted recognition under
regulation 4C (2) of the Indian Boiler Regulations, 1950 as a WELL KNOWN FORGE for the
manufacture of
__________________________________________________________________
for their factory at________________________________
________________________________
_________________________________
_________________________________
This certificate is valid for five years, i.e. upto_______________________
Validity is subject to the adherence to the quality control prescribed under the provisions of the
Indian Boiler Regulations,1950.
__________________
Date of Issue
Certificate No.___________
______________
Secretary
73
FORM XVI-F
[See regulation 4C (2)]
National Emblem
Serial No.
File No
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR WELL KNOWN TUBE MAKER
This is to certify that the Inspection and Quality Management System of:
M/s
__________________________
__________________________
__________________________
has been evaluated by the Central Boilers Board and has been granted recognition under
regulation 4C(2) of the Indian Boiler Regulations, 1950, as a WELL KNOWN TUBE MAKER
for the manufacture of Tubes of Sizes from _______________________________ to
________________________________
__________________________________________________________________
for their factory at________________________________
________________________________
_________________________________
_________________________________
This certificate is valid for five years, i.e. upto_______________________
Validity is subject to the adherence to the quality control prescribed under the provisions of the
Indian Boiler Regulations, 1950.
_______________
Date of Issue
Certificate No.__________
_______________
Secretary
74
FORM XVI-G
[See regulation 4C (2)]
National Emblem
Serial No.
File No
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR WELL KNOWN PIPE MAKER
This is to certify that the Inspection and Quality Management System of:
M/s
__________________________
__________________________
__________________________
has been evaluated by the Central Boilers Board and has been granted recognition under
regulation 4C(2) of the Indian Boiler Regulations, 1950, as a WELL KNOWN PIPE MAKER for
the manufacture of pipe of sizes from _________________________________ to
_______________________________
__________________________________________________________________
for their factory at________________________________
________________________________
_________________________________
_________________________________
This certificate is valid for five years, i.e. upto_______________________
Validity is subject to the adherence to the quality control prescribed under the provisions of the
Indian Boiler Regulations, 1950.
_______________
Date of Issue
Certificate No.____________
_______________
Secretary
75
FORM XVI-H
[See regulation 4C (2)]
National Emblem
Serial No.
File No
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL AS WELL-KNOWN MATERIAL
TESTING LABORATORY
This is to certify that after evaluation of the inspection and material testing system of the
following laboratory, the Central Boilers Board has granted recognition to it under subregulation (2) of regulation 4C of the Indian Boiler Regulations, 1950, as a Well-known Material
Testing Laboratory.
M/s
_________________________
_________________________
_________________________
__________________________________________________________________
This certificate is valid for five years, i.e. upto____________________
__________________________________________________________________
Note:- The recognition will be as per the standards specified under the provisions of the Indian
Boiler Regulations, 1950.
________________
Date of Issue
Certificate No.____________
_______________
Secretary
76
FORM XVI-I
[See regulation 4C (2)]
National Emblem
Serial No.
File No
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL AS WELL KNOWN REMNANT LIFE ASSESSMENT
ORGANISATION
This is to certify that after evaluation of the inspection and material testing system of the
following firm, the Central Boilers Board has granted recognition to it under sub-regulation (2)
of regulation 4C of the Indian Boiler Regulations, 1950 as a Well Known Remnant Life
Assessment Organisation.
M/s._____________________
_________________________
_________________________
__________________________
This certificate is valid for five years, i.e. upto____________
_______________
Date of Issue
Certificate No.____________
_______________
Secretary”.
77
FORM XVII
CERTIFICATE OF MANUFACTURE AND TEST FOR CERTIFICATE OF MANUFACTURE
AND TEST FOR SMALL INDUSTRIAL BOILERS INCLUDING SMALL INDUSTRIAL
SOLAR BOILERS
(Manufactured Under Chapter XIV)
1.
Maker’s
Name
………………………
…………………………………………………….
Year
of
Make
2. Manufactured for ………………………………………………………………………………………….
3. Location of Installation …………………………………………………………………………………….
4. Boiler Identification …………………………… Competent Person’s stamp …………………………
5. Drawing No. …………………………………… Alteration No. …………………………………………
5A. Design Code ………………………………… Working Pressure (kg/Cm2) …………………………
6. Size of Boiler
Length (Meters)
Width (Meters)
Height (Metres)
Diameter (Metres)
7. Shell/Furnace/Tube Plates/Flange Details
Material Specification
CHEMICAL COMPOSITION
C
Si
Mn
P
MECHANICAL PROPERTIES
S
Y
S
U.T.S.
%
EL.
Shell ………………………………………………………………………………………………………………..
Furnance …………………………………………………………………………………………………………..
Tube Plates ………………………………………………………………………………………………………..
Flange ……………………………………………………………………………………………………………..
Boiler Tubes/Pipe/Pads Details …………………………………………………………………………………
Diameter Thickness Material
Specification
CHEMICAL COMPOSITION
C
Si
Mn
P
S
MECHANICAL PROPERTIES
Y
S
U.T.S.
%
Tube
……………………………………………………………………………………………………………
Pipes …………………………………………………………………………………………………………..
Pads ……………………………………………………………………………………………………………
8. Volumetric Capacity
9. Heating Surface (Sq. Metres)
10. Nozzle connection
(a) Steam Outlet ……………………………………………………………………………
(No.
Size
and Type of Nozzles)
(b) Safety Valve …………………………………………………………………………….
(No.
Size
78
and Type of Nozzles)
EL.
(c) Auxiliary (Air vent) …………………………………………………………………..
(No.
Size
and Type of Nozzles)
(d) Blowoff Valve ……………………………………………………………………………
(No.
Size
and Type of Nozzles)
(e) Feed Valve ……………………………………………………………………………
(No.
Size
and Type of Nozzles)
11. Shop Hydro Test Pressure (Kg. Cm2) ……………………… Date …………………………………..
Signature of Manufacturer
We certify that the above boiler constructed under our supervision and inspected at various stages of construction by
the Competent Person and that the construction, workmanship were satisfactory as per Indian Boiler Regulations.
Inspecting Officer
Signature of Inspecting Authority
Dated ………… this ………… Day of ………… 20……
79
“FORM XVIII
[See regulation 392(4)]
QUESTIONNAIRE FORM FOR REPAIRER OF BOILERS/ECONOMISER/STEAM LINE/FEED
WATER LINES
1. (a) Registered name of the firm and its permanent address………………………………………………
(b) Address of the workshop:
2. Year of establishment ……………………………………………………………………………………..
3. Classification applied for—
(a) Special Class (For any Boiler Pressure)
(b) Class I (For Boiler Pressure upto 125 kg.cm2)
(c) Class II (For Boiler Pressure upto 40 kg./cm2)
(d) Class III (For Boiler Pressure upto 17.5 kg/cm2)
4. Type of jobs executed by the firm earlier, with special reference to their maximum
working pressure, temperature and the materials involved, with documentary evidence
…………………………………………………………………
5. (a) Whether the firm has ever been approved by any
Boilers’ Directorate/Inspectorate? If so, give details……………………………………………………………
(b) Has your request for recognition as a repairer under Indian Boiler Regulations, 1950
been rejected by any Authority? If so, please give details……………….. ………………….
6. Whether having rectifier/generator, grinder, general tools
and tackles, dye penetrant kit, expander and measuring
instruments or any other tools and tackles under regulation
392(5)(i).
……………………………………………
7. Detailed list of technical personnel with designation,
educational qualifications and relevant experience (attach
copies of documents) who are permanently employed with
the firm
……………………………………………………………………
8. How many working sites can be handled by the firm
simultaneously? …………………………………………………………………………………………….
9. Whether the firm is prepared to execute the job strictly in
80
conformity with the regulations and maintain a high
standard of work?……………………………………………………………………………………………………
10. Whether the firm is prepared to accept full responsibility for
the work done and is prepared to clarify any controversial
issue, if required?……………………………………………………………………………………………………
11. Whether the firm is in a position to supply materials to
required specification with proper test certificates if asked
for?
…………………………………………………
12. Whether the firm has an internal quality control system of
their own? If so, give details……………………………………………………………………………………
13. List of welders employed with copies of current certificate
issued by a Competent Authority under the Indian Boiler
Regulations, 1950.
……………………………………………
Date …………………
Place ………………..
Name & Signature of the authorised signatory
of the firm with stamp
Note 1: The recognition of the firm as a repairer shall be for a period of two years,
thereafter they shall apply for renewal of their recognition at least two months
before the expiry of the said period.
Note 2: In case the repairer is found violating the provisions of the Act or Regulations
knowingly or unknowingly, the firm shall be blacklisted under intimation to Chief
Inspectors or Directors of Boilers of all the States/Union territories and renewal
shall not be done in any case.”.
81
“FORM XIX
[See regulation 376(ff) and 376(fff)]
DETAILS TO BE FURNISHED ALONGWITH APPLICATION FOR INSPECTION OF BOILER
AFTER TWELVE/TWENTY FOUR MONTHS OF THE CERTIFICATION UNDER REGULATION
390 AS PER APPENDIX ‘JA’ AND APPENDIX ’JB’
1. Name and address of the owner …………………………………………………………………………
2. Registry number of the boiler
…………………………………………………………………………
3. Steam pressure and temperature
…………………………………………………………………….
4. Rate of steam generation …………………………………………………………………….……………
5. Heating surface …………………………………………………………………….………………………
6. Year of make
…………………………………………………………………….……………………….
7. Brief description of boiler …………………………………………………………………….……………
8. Type of construction (Whether riveted or welded) ……………………………………………………
9. Whether fired or waste heat boiler ……………………………………………………………………….
10. Date of registration …………………………………………………………………………………………
11. Details of past exemption granted by the Government, if
any
………………………………………
12. Date of last annual inspection ……………………………………………………………………………
13. Expiry date of current certificate
………………………………………………………………………
14. Working pressure at which last certificate was issued …………………………………………………
15. Details of past repairs (year-wise) ……………………………………………………………………….
16. Remark as entered in the last certificate ………………………………………………………………
17. Quality of boiler feed water
……………………………………………………………………………
18. Whether requisite number of feed pumps are in
satisfactory working condition at present?…………………………………………………………………………
19. Number of safety valves mounted on shell/drum and super
heater………………………………..
20. Total number of soot blowers provided in boiler
82
……………………………………………………
21. Number of soot blowers in working condition …………………………………………………………
22. Whether safety valves are blowing satisfactorily at or below
design pressure?……………………………………………………………………………………………………
23. Whether safety valve assembly is free from jamming as
verified by operating casing lever?…………………………………………………………………………………
24. Whether high and low water level alarm is in good
condition?
………………………………………
25. Whether main steam stop valves, feed check valves, blow
down valves and master pressure gauge in working
condition?
…………………………………………….
26. Whether additional requirements for automatic boilers as
per regulation 281A are complied with? (If ‘No’, give
details)
…………………………………………….
27. Last date of calibration for master pressure gauge,
temperature indicator/recorder for superheater, hot reheat,
cold reheat and main steam line.……………………………………………………………………………………
28. (a) Last date when boiler protection devices were satisfactorily tested
and details thereof …………………………………………….
(b) Last date when boiler protection devices were tested by
simulation………………………………………………………………………………
29. Details of boiler stoppages in
reasons and remedies thereof.
last twelve months with
…………………………………
30. Present irregularities in instruments and controls if any
observed in control-room of boiler house.…………………………………………………………………………
31. Details of present boiler leakage. ………………………………………………………………………
32. Present operating pressure of the boiler ………………………………………………………………
33. Whether water quality is tested on-line (enclose copy of
test report showing values of analysis including Total
Dissolved Solids(TDS)
…….……………………………………
34. State at what intervals such test is carried out …………………………………………………………
35. When boiler was last opened for internal and/or external
cleaning?
83
…………………………………
36. State at what intervals such cleaning is carried out.……………………………………………………
37. Whether there was any shut down since last inspection
when the boiler could have been offered for inspection?…………………………………………………………
38. Whether working pressure of the boiler ever exceeded in
the past beyond certified limit? If any, give details……………………………………………………………….
39. Details of boiler accident which took place in the past, if
any
…………………………………………
40. List of Boiler Operation Engineers/Attendants …………………………………………………………
41. Irregularities, if any, noticed in the past in compliance of
the Act.
…………………………………………………………………………………………
42. Whether guidelines laid down by Central Boilers Board for
granting exemption to the waste heat boilers are fulfilled or
not?
……………………………………
General Manager (Generation)
Remarks of the Competent Person who verified correctness of above statement paying check visit to the Boiler
House.
Competent Person”.
84